Cap for battery terminal

ABSTRACT

Disclosed is a non-lead conductive cap for a battery terminal and battery. The battery may comprise a battery housing and a positive and negative terminal, the positive and negative terminal being accessible through the battery housing; wherein the positive and negative terminal further comprise an electrically conductive cap mounted on both the positive and negative terminal, wherein the electrically conductive cap does not comprise lead.

CROSS-REFERENCE TO EXTERNAL APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/638,641 filed Mar. 5, 2018, entitled CAP FORBATTERY TERMINAL, the entire contents of which is hereby incorporated byreference in its entirety.

FIELD OF INVENTION

The present disclosure relates to batteries. The present disclosure morespecifically relates to external electrical connections for batteries.

BACKGROUND

In batteries with multiple cell elements, the cells are connected inseries by conductive straps. The straps also connect the cells to apositive terminal and a negative terminal. These terminals areaccessible outside the battery housing. These terminals allow for avehicle (or other application) to connect to the battery for use. Theconductive straps and terminals comprise a conductive material.Typically, in a lead-acid battery, this conductive material is comprisedof lead.

Lead is a heavy metal and considered to be toxic. Any lead surfaceexposed to the environment is a potential source of contamination. Useof lead is therefore prohibited in many applications.

Known lead-acid batteries require interaction between a consumer ortechnician with the lead terminals in order to connect, change, orotherwise maintain the battery. Certain governmental bodies areadvancing tighter regulation of lead in lead-acid batteries. Forexample, the European Union and the State of California have exploredregulations about lead exposure as it relates to lead-acid batteries.For example, Department of Toxic Substances Control's (DTSC) inCalifornia is actively evaluating whether it should identify lead-acidbatteries as a Priority Product under the Safer Consumer Products (SCP)program. Of particular concern is the exposure of consumers to lead dustby inhalation and ingestion during consumer use and replacement.

SUMMARY

Therefore, various embodiments of solutions are disclosed which seek toremedy the above deficiencies. More specifically, disclosed are variousembodiments which may allow for access to the functionality of thebattery without requiring a user to interact with or be exposed to thelead.

The present invention according to various embodiments relates to a leadacid battery having a positive terminal and a negative terminal. Thepositive and negative terminal may be designed, according to variousembodiments of the invention, to limit exposure of any lead provided inthe terminal.

The positive and negative terminals may be provided, according tovarious embodiments of the invention, with conductive covers (forexample, electrically conductive caps) to limit exposure to leadprovided in the terminal. In other words, the disclosed invention mayallow for exposed surfaces of the battery to be free of lead.

The disclosed battery, terminal, and method, in one or more examples ofembodiments, allows for electrical and mechanical attachment to anon-lead terminal surface of a battery. This may prevent or limitexposure to lead by consumers and technicians who work with a battery.The disclosed battery, terminal, and method may comprise a cover for abattery terminal having a conductive portion. The cover may comprise acap. The cap, in various embodiments, may allow for attachment afterformation of the battery. The cap may allow for an electrical connectionto the battery terminal without exposure to a lead terminal. The cap mayallow for this connection on a standard battery terminal.

Disclosed is a battery having a battery housing and a positive andnegative terminal, the positive and negative terminal being accessiblethrough the battery housing; wherein the positive and negative terminalfurther comprise an electrically conductive cap mounted on both thepositive and negative terminal, wherein the electrically conductive capdoes not comprise lead. Further disclosed is a battery wherein theelectrically conductive portion of the cap comprises a conductive cage.Further disclosed is a battery wherein the cap is comprised of amaterial selected from the group of copper, brass, stainless steel, ornickel. Further disclosed is a battery wherein the cap is furthercomprised of a polymer or resin. Further disclosed is a battery whereinthe cap further comprises an overmold. Further disclosed is a batterywherein the cap further comprises torque ribs.

Disclosed is a battery comprising: a housing comprising a cover and abattery element; a terminal facilitating electrical connection with thebattery element which extends through the cover; and anelectrically-conductive cap which receives a terminal; and wherein theelectrically-conductive cap does not comprise lead. Further disclosed isa battery wherein the terminal comprises lead and theelectrically-conductive cap covers all terminal lead. Further disclosedis a battery wherein electrically-conductive cap couples to the terminalby way of a friction fit. Further disclosed is a battery wherein theelectrically-conductive cap connects to the using one or more componentsselected from the group of thermal press-fit, adhesive, glue, spinwelding, heat sealing, laser welding, or an overmolded ring. Furtherdisclosed is a battery wherein the electrically-conductive cap comprisesa conductive cage. Further disclosed is a battery wherein theelectrically-conductive cap is comprised of a material selected from thegroup of copper, brass, stainless steel, or nickel. Further disclosed isa battery wherein the electrically-conductive cap is further comprisedof a polymer or resin.

Also disclosed is a battery having a battery housing and a terminal, theterminal being accessible through a battery housing; wherein theterminal does not comprise lead. Further disclosed is a battery whereinthe housing comprises a cover, and the cover comprises a bushing, thebushing receiving the terminal. Further disclosed is a battery whereinthe bushing comprises lead and is provided below a surface of the cover.

These and other features and advantages of various embodiments ofsystems and methods according to this invention are described in, or areapparent from, the following detailed description of various exemplaryembodiments of various devices, structures, and/or methods according tothis invention.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a battery having a terminal, according to various examplesof embodiments.

FIG. 2 shows a section of a battery having a known bushing and terminal,according to various examples of embodiments.

FIG. 3A shows a cross-section of a first cap for a battery terminal,according to various embodiments.

FIG. 3B shows a second view of the cap of FIG. 3A for a battery terminalaccording to various embodiments.

FIG. 4 shows a terminal cap for a battery terminal for use with one ormore embodiments of a cap disclosed herein, according to variousembodiments.

FIG. 5 shows a number of views of a terminal cap for a battery terminaland housing according to various embodiments.

FIG. 6 shows an example bushing for a battery terminal, according tovarious embodiments.

FIG. 7 shows a non-lead battery terminal and bushing, according tovarious embodiments.

FIG. 8 shows another non-lead battery terminal, according to variousembodiments.

It should be understood that the drawings are not necessarily to scale.In certain instances, details that are not necessary to theunderstanding to the invention or render other details difficult toperceive may have been omitted. It should be understood, of course, thatthe invention is not necessarily limited to the particular embodimentsillustrated herein.

DETAILED DESCRIPTION

Disclosed are various embodiments of a battery, battery terminal, andmethod for manufacturing the same. The disclosed embodiments of abattery, battery terminal, and method allow for access to anelectrically-conductive terminal surface and battery functionalitywithout exposure to lead on the surface of the terminal.

FIG. 1 shows a battery 101 having a housing 103. The housing 103 mayfurther comprise a surface 105 (for example, a cover or lid). Protrudingfrom the cover 105 can be seen two terminals 107. While terminals 107are generally specified, the terminals 107 may comprise a positiveterminal 109 or a negative terminal 111 (the phrase “terminal” may beused herein to describe a positive terminal 109, negative terminal 111or both unless otherwise particularly specified). While the cover 105 isshown on a top of the battery 101 with the terminals 107 protrudingtowards an upper edge of the page, it should be understood the cover 105and terminals 107 may be provided on any orientation, such as a side toallow access to terminals 107.

The various elements of the battery 101, the battery housing 103, thebattery cover 105, and the cell containers may be made of a wide varietyof known materials. For example, the cover 105, container/housing 103,and/or various components may be made of any polymeric (e.g.,polyethylene, polypropylene, a polypropylene containing material, etc.)or composite (e.g., glass-reinforced polymer) material. For example, thecontainer may be made of polypropylene-containing material (e.g., purepolypropylene, co-polymers comprising polypropylene, polypropylene withadditives, etc.). Such polymeric material is relatively resistant todegradation caused by acid (e.g., sulfuric acid) provided within cellsof the container or housing 103.

FIG. 2 shows an example of a section of a battery 101. The battery 101includes a battery element 113 coupled to an end strap 115 which leadsto a terminal post 117. The terminal post 117 extends through a bushing119 provided within the cover 105 of the battery housing 103. This isone non-limiting example of a battery 101 which may be used with thedevices (e.g. bushing 119, terminal post 117, and/or cover 105),systems, and methods described herein.

FIG. 3A shows a cross-section of a first cap 251 for a battery terminal107 for a lead-acid battery 101, according to various embodiments. Thecap 251 may be understood as sized to accept a battery terminal 107(such as a positive terminal 109 or negative terminal 111) protrudingfrom a lid or cover 105 of a battery housing 103. The cap 251 may beprovided on top of a terminal post 117 and bushing 119, which may, forexample be welded together to form a terminal 107 and facilitateconnection between the terminal 107 and an electrical connector (notshown). The cap 251 may be understood to be electrically conductive, forexample, but not limited to, in an electrically conductive portion (suchas, but not limited to, a conductive cage 259).

The cap 251 may comprise at least an electrically conductive portion. Invarious embodiments, the electrically conductive portion comprises aconductive cage 259. The conductive cage 259 may generally comprisecopper or other conductive metal. The conductive cage 259 may surround abattery terminal 107. Therefore, a bottom 253 of the cap 251 may beprovided onto a top surface of a battery cover 105. In one or moreexamples the conductive cage 259 is filled, spaced apart, or alternateswith a portion 256 which may be non-conductive comprising a substancesuch as a polymer or resin, for example, polypropylene. In other words,the sides 255 of cap 251 may comprise both a polymer or resin portion256 as well as conductive material (conductive cage 259). Thesesubstances may be alternating, in various embodiments, about the cap259. A top 257 and bottom 253 of the cap 251 may be comprised of asimilar substance. The conductive cage 259 may provide a conductivematerial that is exposed on an internal surface (interior 261) as wellas an external surface 263 of the cap. It should be understood the cap251 comprising a conductive cage 259 provides electrical contact bothwith a terminal post provided within the cap and a connector providedexternally to the cap. The cap 251 comprising a conductive cage 259including the filled substance 256 therefore may facilitate connectionby a standard battery connector with the terminal while preventingexposure to the lead terminal 107.

FIG. 3B shows a second view of the cap of FIG. 3A. In FIG. 3B, theconductive cage 259 comprises a number of vertical ribs spacedcircumferentially around the sides 255 of the cap 251 which, when placedon battery 101, surround the terminal 107 (for example, positiveterminal 109 or negative terminal 111). While vertical ribs are shown,other patterns such as a diagonal, spiral, horizontal ribs, or the likeshould be understood as within the scope of this disclosure. Again, theconductive cage 259 may be separated or filled in by a portion 256comprising a substance such as a polymer or resin, for examplepolypropylene. Likewise, a top 257 and bottom 253 of the cap 251 mayalso be seen and may comprise such a polymer or resin.

Again, the conductive cage 259 may comprise a conductive material, whichmay include, but are not limited to, materials such as copper, brass,stainless steel, or nickel, or alloys/combinations thereof and the like.In various embodiments, the cap 251 may comprise a copper cage 259filled with a material such as polypropylene 256. To this end, the cage259 may allow for injection-molding of the non-conductive portions ofthe cap (top 257, bottom 253, spaces between ribs 256).

In one or more examples of embodiments, the cap 251 may be attached to abattery housing 103 (for example, cover 105) after being provided on topof a battery terminal 107. For example, the base or bottom 253 mayfasten to the top (cover 105) of the battery 101. The cap 251 may, invarious embodiments, be glued/molded/bonded to top 105 of battery 101.Then, a connector may be attached to the cap 251, facilitatingconnection with the battery 101 by way of the terminal 107.

FIG. 4 shows another example embodiment of an electrically conductivecap 351 for a battery terminal 107, according to various embodiments.The electrically conductive cap 351 may be understood as provided on topof a battery terminal 107 in an interior 361 of the cap. The cap 351 maybe comprised of an electrically conductive material that is resistant toacid. In one or more examples of embodiments, the cap 351 may becomprised, for example, of copper, brass, stainless steel, nickel,alloys or combinations thereof, or the like. The cap 351 may becomprised entirely of electrically conductive material or the cap 351may include non-conductive components. For example, the cap 351 mayinclude an overmolded ring 365 (for example, an overmolded resin ring)for facilitating fastening to the surface of a cover 105. In variousembodiments, the overmolded ring 365 facilitates the joint connection tothe battery cover 105. In various embodiments, connection to an exteriorsurface of the battery cover 105 is provided using an adhesive or aplastic that is molded over top of the cap 351. In various embodiments,the cap 351 is stamped out of a conductive material.

The cap 351 may further comprise a number of torque ribs 359. The torqueribs 359 may be stamped or otherwise formed into the cap 351. The torqueribs (or, in various embodiments, inward dimples) 359 may compress intothe lead post 107 by an attached battery clamp providing the electricalconnection and torque resistance. The cap 351 material may have athickness sufficient to resist the clamping torque and abrasion. Thisway, the cap 351 may maintain coverage of the lead terminal 107 andprevent exposure thereof. In various embodiments, the thickness of thecap material may be from approximately 0.050 mm to approximately 1.5 mm.The torque ribs 359 may likewise be comprised of a conductive material.

As an alternative, solder 367 may be provided on the inside of the cap351. The solder 367 may be tinned to the cap 351. The solder 367 mayfacilitate an electrical connection (i.e. a soldered connection) betweenthe cap 351 and the terminal 107. The cap 351 may comprise a conductivematerial other than lead (for example, but not limited to, copper,brass, stainless steel, nickel, alloys or combinations thereof, or thelike). The solder 367 may be localized to one surface (for example,under the top 357 of the cap 351) or on more than one or all surfaces(e.g. top 357, sides 355, and/or bottom 353).

FIG. 4 also shows a number of attachment mechanisms for providing thecap 351 onto a housing 103 or cover 105. For example, the cap 351 mayattach by way of an overmold 365. The overmold 365 may allow forattachment by heating of a polypropylene or plastic or other suitablematerial, for example, between a bottom of the conductive material 353and a top of a battery housing 103 or cover 105. While heating of theovermold 365 would facilitate connection between the cap 351 and batteryhousing 103 in various embodiments, other fastening mechanisms may beused to seal the cap 351 to the battery housing 103. For example, asdescribed herein, an adhesive provided on a bottom surface 369 of thecap 351 may be used. In various embodiments, the cap 351 is sealed tothe housing 103 after being positioned over the terminal post 107. Thepositioning of various embodiments of the cap (251, 351, 451, etc.)disclosed herein may be performed after terminal post weld (in otherwords, when bushing 119 and end strap 115 are joined to produce theterminal 107) or after full battery formation, in various embodiments.

For example, the cap 351 may be joined to the cover 105 by a joiningprocess such as spin welding. As previously described, the cap mayfurther comprise an overmolded ring 365 that can be heat sealed or laserwelded to the cover 105. Alternately, the electrically conductive cap351 may have an adhesive at the base (or bottom) (e.g. 353) which maythen be attached to the surface of the battery cover 105. Somecombination of the above may also be used. In addition, for attachment,the cap 351 may first be heated, then pressed onto the terminal 107.Also, torque ribs 359 in the heated cap 351 could be melted into thesofter lead of the terminal 107 to make a robust connection.

In addition, as shown in FIG. 6, a bushing or terminal 507 (for example,positive and negative terminals) could also be designed with somegrooves which may key into torque ribs (for example, 359 and 459)provided on the cap (351, 451).

FIG. 5 shows various embodiments of another electrically conductiveterminal post cap or cover 451. Again, the cap 451 may be comprised of aconductive material (for example, copper, however, further materials maybe contemplated as within the scope of this disclosure). In variousembodiments, the cap 451 may be slightly smaller in inner dimensions ordiameter 467 compared to the battery terminal diameter 469 on which thecap 451 sits. In other words, in one or more examples of embodiments,the inner diameter of the cap (b) 467, in various embodiments, may besmaller than a diameter of a terminal (a) 469. This may provide a tightor friction fit of the cap on the terminal. In various embodiments, thecap 451 may fit onto the terminal by way of a thermal press-fit.

The cap 451 further may further comprise a sealing ring 465 to beattached, for example, by welding into the surface of the batteryhousing cover 105. The sealing ring 465 and ring detail 471 may aid inproviding a tight connection to the housing 103. The tight connectionmay aid in preventing exposure of lead of the terminal 107 to theenvironment. In other words, in various embodiments, the heated metalcap 451 may be pressed into the housing (which may, in variousembodiments, comprise polypropylene) to weld to the housing with whichring 465 and ring detail 471 allow for a tight seal between the cap 451and housing 105.

The cap 451 may further comprise one or more small wings 459 for torque.A cross-section of the cap 451 having the wings 459 may be seen in asreference “P” of FIG. 5. Further, the cap 451 may comprise one or morehorizontal structures to prevent removal of the cap 451. In variousembodiments, horizontal structures provided within the cap 451 maycollide with the lead of the bushing 107 it covers when the metal cap451 is pushed down for welding. Collision may not occur, for example, ifthe cap is heated such that the dimension is enlarged during insertionbased on temperature elongation (thermal expansion and contraction) asdescribed further herein. In addition, in various embodiments, the cap451 may comprise a number of vertical wings or ribs inside of the cap ina way that when pressing the cap down the cap is slightly screwed intothe bushing. A slight turn may, for example, assist in further seatingthe cap 451 on the terminal 107.

One or more examples of additional attachment mechanisms for use with acap (for example, 251, 351, 451) as described herein will now bedescribed. The cap may first be heated, then pressed onto the terminal.Thermal expansion and contraction by the cap (for example, 251, 351,451) may ensure a tight connection between the terminal 107 (post,bushing) and cap when the terminal 107 is pressed upon from above. Invarious embodiments, heating the cap (e.g. 251, 351, 451) may allow forforming of the cap (for example, 251, 351, 451) into the lid 105, forexample, using a heat sealing ring (for example, 465) on the cap forproviding into the housing 103 or lid 105, which may comprisepolypropylene. In other words, the sealing ring (for example, 465) mayform into melted polypropylene or like material comprising the housingcover 105. The heated cap may allow for melting of the lid 105 andsealing of the connection. In addition, the heated cap may allow forattachment to the cap (for example, 251, 351, 451) to the terminal 107by way of thermal expansion.

In various embodiments, the cap (for example, 251, 351, 451) maycomprise an undercut. The lid 105 may be modified, in variousembodiments, to accept the cap. For example, a depression may beprovided in the lid to accept the cap. In various embodiments, the cap(for example, 251, 351, 451) may “dig into” the lid or cover 105material to facilitate a tight seal between the cap and housing cover.

The torque ribs 359 shown in FIG. 4 could also be included in otherembodiments of the cap disclosed, for example, in the design describedin FIG. 5, and contribute fastening of that cap 451 to the terminal 107.Torque ribs provided into a heated cap could likewise be formed into thesofter lead (terminal 107) to make a robust connection.

In addition to the examples described above, the cap (for example, 251,351, 451) may be attached to the terminal (for example, 107, 507) by anumber of methods including welding, solder tin etc., pressure, torqueribs, and the like. The cap may be attached to the housing (e.g.polypropylene lid) by a number of methods including by heat, adhesive,glue, spin welding, heat sealing, laser welding, an overmolded ring atthe cap (for example, an overmolded polypropylene ring), and the like.In various embodiments, the cap and cover 105 connection may comprise apressure-sensitive adhesive.

Caps, such as those provided above (for example, 251, 351, 451), mayadvantageously allow for attachment after battery formation. Forexample, whether the terminal is provided with a cap may be based onbattery distribution. In one non-limiting example, providing theterminals of batteries with a cap may be made after formation but priorto a battery being shipped to a particular location. This allows foradvantages in the manufacturing process. The disclosed cap has a numberof additional advantages. The cap may facilitate additional acidtightness due to the sealing ring. The cap may allow forpost-manufacturing attachment of a cap as necessary. The cap may allowfor modifications to a bushing alloy. The cap may allow for reducedexposure to lead of existing and new batteries.

The caps described herein could be used with a modified batteryterminal, in various examples of embodiments. As noted previously andshown in FIG. 6, the bushing or terminal 107 could also be designed withsome grooves 509 to produce bushing or terminal 507 which could key into the torque ribs (for example 359). In other words, in variousembodiments, the bushings or terminal 507 may have grooves 509 whichmate in various embodiments with torque ribs 359. In general, it shouldbe understood the terminal size or design (for example, 107, 507) mayrequire modification to compensate for the thickness of the cap. Inother words, resizing of the terminal due to increased thickness of thecap may be required in order to facilitate connection with standard-sizeelectrical connectors.

FIG. 7 shows a terminal 607, according to various examples ofembodiments. The terminal 607 may be understood to be comprised of anon-lead material (such as, but not limited to, brass, copper alloys,etc.) that is still highly conductive. The terminal 607 may be seen asattaching to the inner electrical path of a battery (for example, theterminal post 617 of a battery 101 (for example, a lead-acid battery))through a cover 605. The attachment may be made through a connector forexample, a stud connector 621. Other methods of connection, such as butnot limited to, a sealed welding operation such as sonic or spin weldingmay be used. The interface between the bushing 607 and the terminal 617may allow for sufficient area to achieve current-carrying requirements.The terminal 617 and associated components therefore may provide alead-free interface for a stamped battery terminal connector in avehicle.

FIG. 8 may be seen to show another version of a terminal as described inFIG. 7. Again, the terminal 707 may be seen received by a bushing 719molded into the cover 705, facilitating connection to the innerelectrical components of the battery by way of terminal 717. Theterminal 707 may be understood to be connected to the bushing 719 belowan exposed surface of the cover 705, resulting in no exposed lead whileallowing connection to meet current-carrying requirements.

The various elements of the battery, the battery housing, the batterycover, and the cell containers may be made of a wide variety ofmaterials as is well known in the art. For example, the cover,container, and/or various components may be made of any polymeric (e.g.,polyethylene, polypropylene, a polypropylene containing material, etc.)or composite (e.g., glass-reinforced polymer) material. For example, thecontainer may be made of polypropylene-containing material (e.g., purepolypropylene, co-polymers comprising polypropylene, polypropylene withadditives, etc.). Such polymeric material is relatively resistant todegradation caused by acid (e.g., sulfuric acid) provided within cellsof the container. The terminal posts, side terminals and connectionmembers may be made of one or more conductive materials (e.g., lead or amaterial containing lead). Likewise, the strap members and end strapsmay be made of one or more conductive materials (e.g., lead or amaterial containing lead).

Known terminals may be comprised, in various embodiments, of a leadalloy. In various embodiments, this alloy may be a substantially purelead and may, in various embodiments, include lead, tin, antimony,calcium, and combinations thereof. The alloy may, as a non-limitingexample, be a lead tin alloy with a tin composition range of 1-4%,1-2.25%, 1-1.5%, and the like. The lead may be virgin lead or highpurity lead or highly purified secondary lead, in various examples ofembodiments.

As utilized herein, the terms “approximately,” “about,” “substantially”,and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims.

It should be noted that references to relative positions (e.g., “top”and “bottom”) in this description are merely used to identify variouselements as are oriented in the Figures. It should be recognized thatthe orientation of particular components may vary greatly depending onthe application in which they are used.

For the purpose of this disclosure, the term “coupled” means the joiningof two members directly or indirectly to one another. Such joining maybe stationary in nature or moveable in nature. Such joining may beachieved with the two members or the two members and any additionalintermediate members being integrally formed as a single unitary bodywith one another or with the two members or the two members and anyadditional intermediate members being attached to one another. Suchjoining may be permanent in nature or may be removable or releasable innature.

It is also important to note that the construction and arrangement ofthe system, methods, and devices as shown in the various examples ofembodiments is illustrative only. Although only a few embodiments havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements show as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied (e.g. byvariations in the number of engagement slots or size of the engagementslots or type of engagement). The order or sequence of any process ormethod steps may be varied or re-sequenced according to alternativeembodiments. Other substitutions, modifications, changes and omissionsmay be made in the design, operating conditions and arrangement of thevarious examples of embodiments without departing from the spirit orscope of the present inventions.

While this invention has been described in conjunction with the examplesof embodiments outlined above, various alternatives, modifications,variations, improvements and/or substantial equivalents, whether knownor that are or may be presently foreseen, may become apparent to thosehaving at least ordinary skill in the art. Accordingly, the examples ofembodiments of the invention, as set forth above, are intended to beillustrative, not limiting. Various changes may be made withoutdeparting from the spirit or scope of the invention. Therefore, theinvention is intended to embrace all known or earlier developedalternatives, modifications, variations, improvements and/or substantialequivalents.

The technical effects and technical problems in the specification areexemplary and are not limiting. It should be noted that the embodimentsdescribed in the specification may have other technical effects and cansolve other technical problems.

The invention claimed is:
 1. A battery having a battery housing and apositive and negative terminal, the positive and negative terminal beingaccessible through the battery housing; wherein the positive andnegative terminal further comprise an electrically conductive capmounted on both the positive and negative terminal, wherein theelectrically conductive cap does not comprise lead.
 2. The battery ofclaim 1, wherein the electrically conductive cap comprises anelectrically conductive portion comprising a conductive cage.
 3. Thebattery of claim 1, wherein the cap is comprised of a material selectedfrom the group of copper, brass, stainless steel, or nickel.
 4. Thebattery of claim 3, wherein the cap is further comprised of a polymer orresin.
 5. The battery of claim 1, wherein the cap further comprises anovermold.
 6. The battery of claim 1, wherein the cap further comprisestorque ribs.
 7. The battery of claim 1, wherein theelectrically-conductive cap is a lead-free electrically-conductive cap.8. A battery comprising: a housing comprising a cover and a batteryelement; a terminal facilitating electrical connection with the batteryelement which extends through the cover; and an electrically-conductivecap which receives the terminal; wherein the electrically-conductive capdoes not comprise lead.
 9. The battery of claim 8, wherein the terminalcomprises an exposed portion comprising lead and theelectrically-conductive cap covers all of the terminal lead.
 10. Thebattery of claim 9, wherein t e electrically-conductive cap couples tothe terminal by way of a friction fit.
 11. The battery of claim 9,wherein the electrically-conductive cap connects to the cover using oneor more components selected from the group of thermal press-fit,adhesive, glue, spin welding, heat sealing, laser welding, or anovermolded ring.
 12. The battery of claim 8, wherein theelectrically-conductive cap comprises a conductive cage.
 13. The batteryof claim 8, wherein the electrically-conductive cap is comprised of amaterial selected from the group of copper, brass, stainless steel, ornickel.
 14. The battery of claim 8, wherein the electrically-conductivecap is further comprised of a polymer or resin.
 15. The battery of claim8, wherein the electrically-conductive cap is a lead-freeelectrically-conductive cap.
 16. A battery having a battery housing anda lead terminal having an exposed portion accessible from an exterior ofthe battery housing; wherein the battery further comprises anelectrically-conductive cap having a lead-free external surface whichreceives the lead terminal and covers the entire exposed portion of thelead terminal.
 17. The battery of claim 16, wherein the electricallyconductive cap comprises an electrically conductive portion comprising aconductive cage.
 18. The battery of claim 16, wherein theelectrically-conductive cap connects to a cover of the housing using oneor more components selected from the group of thermal press-fit,adhesive, glue, spin welding, heat sealing, laser welding, or anovermolded ring.
 19. The battery of claim 16, wherein the batterycomprises a second terminal and second electrically-conductive cap. 20.The battery of claim 19 wherein any exposed surface of the battery islead-free.